RS-5 PERFORMANCE EXHAUST SYSTEM
RESEARCH&DEVELOPMENT OF AMERICA, INC.
5420 DANIELS STREET STE A, CHINO CA. 91786 · (800)634-9166 · (909)628-4722 · FACSIMILE (909)591-2198
RS -5 PERFORMANCE EXHAUST SYSTEM
RACE ONLY FULL SYSTEM
RACE ONLY FULL SYSTEM WITH ENDCAP
THIS PRODUCT IS DESIGNED FOR USE IN CLOSED COURSE
RACING AND IS NOT INTENDED FOR HIGHWAY USE.
NOTE: IN THE STATE OF CALIFORNIA, IT IS ILLEGAL TO MODIFY THE EMISSION CONTROL SYSTEM, WHICH INCLUDES THE FUEL INJECTION OF ANY VEHICLE.
Caution: Exhaust system can be extremely hot. Let motorcycle cool down
before beginning installation.
Note: Read through all instructions before beginning installation.
8mm, 10mm, 12mm, and 14mm sockets
Ratchet and Extension
12mm and 17mm wrench
4mm and 5mm Allen wrench
Sharp Scissors & Pen
1 Remove left and right cowling (See Fig. 1).
2 Remove lower radiator bracket and tilt radiator forward
slightly (See Fig. 2 and 3).
Note: Cardboard and duct tape can be used to cover the
lower inside portion of the radiator when removing
and installing the header.
3 Remove stock header and exhaust port gaskets and
install new stock exhaust port gaskets (stock
exhaust port gaskets not included).
Note: Check that the distance between header
manifolds are 75.5mm, measured from center to
center. There should be 31.5mm spaces between the
outside diameter of each header tube manifold.
Adjustment to the header tubes may be necessary in
order to ensure the accuracy of this measurement.
4 Slide supplied collector clamp over Yoshimura header
and slide Yoshimura header over stock midpipe
(stock collector to midpipe gasket will not be used).
Connect Yoshimura header to exhaust ports using
stock header nuts.
5 Torque header nuts to 2.3 kg-m (16.5 lb-ft).
6 Torque collector clamp to 1.25 kg-m (9 lb-ft).
7 Wipe down the header with rubbing alcohol to remove
oil and fingerprints. This will prevent tarnishing of
the finish after the exhaust is heated up.
8 Reinstall lower radiator bracket.
9 Reinstall left and right cowlings.
10 Remove right and left black plastic tank side panels (See Fig. 4 and 5).
11 Remove rider seat (One bolt on each side of seat) and passenger seat.
12 Remove rear cowling: Remove 7 bolts, 3 plastic snap fasteners, and 1 snap-out (See Fig. 6 and Fig. 7). Disconnect
tail light connector and remove rear cowling.
13 Unbolt and remove rear fender and the left and right turn signal assemblies: Licence plate running light connector
and turn signal connectors must be disconnected prior to removal.
14 Unbolt and remove black plastic midpipe heat shield (See Fig. 8).
15 Unbolt and remove black plastic tailpipe heat shield (See Fig. 9).
16 Remove black rubber insulators and then remove the metal heat
Shield that covers the tailpipe exhaust valve (See Fig. 10).
17 Disconnect tailpipe exhaust valve cables from tailpipe
(See Fig. 11).
18 Remove aluminum crosspiece from subframe (See Fig. 12).
19 Disconnect exhaust valve cables from exhaust valve actuator
(electric servo motor, see Fig. 13) and remove hexagonal disc.
WARNING!: Do not disconnect servo motor from ECU and do
not allow the servo motor to rotate when removing the bolt
that secures the hexagonal disc to the servo motor. The servo
motor contains plastic gears. If the servo motor rotates while
removing this bolt, the plastic gears inside the servo motor
20 Install Yoshimura bracket using stock bolts and washers (see
Fig. 14). Be careful not to lose the spacers and washers below
the servo motor.
21 Turn key quickly on and off to rotate servo motor until notch
points directly toward the “V” in the Yoshimura EVA stopper
bracket (See Fig. 14).
22 Place stock hexagonal disc and supplied washer onto servo
motor with holes facing the “V” in the Yoshimura stopper
bracket (See Fig. 15).
23 Place Yoshimura EVA stopper plate on top of hexagonal disc
and secure with stock bolt (See Fig. 16).
WARNING!: Do not allow the servo motor to rotate while
tightening the stock bolt that secures the EVA stopper plate to
the hexagonal disc. The servo motor contains plastic gears.
If the servo motor rotates while tightening this bolt, the plastic
gears inside the servo motor will strip.
24 Reinstall aluminum crosspiece onto subframe.
25 Start the bike and watch the instrument cluster.
The “FI” light should not light up. If the “FI” light
remains on after the bike is started, please
carefully follow through the installation steps
again (see Fig. 17 for location of “FI” light). If
problem still persists, please call Yoshimura tech.
dept. at (800)634-9166 / in CA (909)628-4722.
Warning: Keep fingers and other body parts
away from the Yoshimura EVA (Exhaust Valve
Actuator) Stopper when turning the key to the
“ON” position and when the bike is running.
Note: The Yoshimura EVA (Exhaust Valve
Actuator) Stopper only prevents problems
resulting from the disconnection of the exhaust
valve cables. Any other problems that would
normally cause the “FI” light to be illuminated
will continue to do so.
26 Remove stock muffler: Loosen midpipe to tailpipe
collector clamp. Remove the two muffler mounting
bolts while supporting the weight of the muffler (be
careful, it’s heavy). Remove muffler. Do not remove
stock midpipe to tailpipe collector clamp and stock
exhaust gasket as they will be used upon reinstallation.
If stock exhaust gasket is damaged, replace with a new
stock exhaust gasket.
27 Install adhesive heat shield to rear under tail section
(see Page 7 for instructions).
28 Slide Yoshimura tailpipe into stock midpipe using stock
collector clamp and stock exhaust gasket.
29 Install supplied muffler clamp heat shield to inside of
muffler clamp. Slide muffler clamp onto muffler and
line up muffler clamp ears with stock muffler mount
location. Use stock bolts and washers and supplied
nuts to secure Yoshimura muffler to the subframe, but
leave loose at this time.
30 Check alignment of exhaust, then torque collector
clamp to 1.25 kg-m (9 lb-ft).
31 Torque muffler clamp bolts and nuts to 2.5 kg-m (18 lbft).
32 Attach rear fender and left and right turn signals to
aluminum Yoshimura rear fender bracket (See Fig. 18).
33 Attach rear fender bracket with attached rear fender and
turn signals to original mounting points on subframe
(See Fig. 19).
34 Reinstall midpipe heat shield, rear cowling, and seats in
reverse order of disassembly. Check for proper
operation of tail light, brake light, and turn signals.
35 It is recommended that the muffler and tailpipe be
wiped down with rubbing alcohol to remove oil and
fingerprints. This will help prevent tarnishing of the
finish after the exhaust is heated up.
36 Check for proper clearance between new exhaust
system and motorcycle. (i.e. subframe, bodywork, etc.)
If any problem is found, please carefully follow through
the installation steps again. If problem still persists,
please call Yoshimura tech. dept. At
(800)634-9166 / in CA (909)628-4722
36 Check for proper clearance between new
exhaust system and motorcycle. (i.e. subframe,
bodywork, etc.) If any problem is found, please
carefully follow through the installation steps
again. If problem still persists, please call
Yoshimura tech. dept. At
(800)634-9166 / in CA (909)628-4722
Note: After starting motorcycle, it is normal for
new exhaust system and muffler to smoke until
oil residue burns off.
Cut out supplied template .
Tape or firmly hold template to adhesive side
(not foil side) of heatshield.
Trace outline of template on heatshield
Use scissors to cut heatshield to outline.
When cutting, keep excess in one piece - the
extra piece will be used later.
Use rubbing alcohol to clean area where
heatshield will be applied.
Remove adhesive backing and apply to
underside of rear fender assembly.
Note: Take a moment to examine how the
heatshield lines up with the features of the
undertail plastic before you begin.
After the heatshield is installed use the scraps
to patch or cover any open areas.
#146202(2,5,7) / #146207(2,5,7)
S = Stock
1 Yoshimura Header
Stainless Steel Race Only
2 Yoshimura Tailpipe
3 RS5 Muffler Assembly
4 Stainless Steel Muffler Clamp
Stainless Steel or Titanium Sleeve use
Carbon Fiber Sleeve use
5 Exhaust Spring, Short
6 Exhaust Spring, Medium
7 8mm Nut
8 Stainless Steel Collector Clamp
** Large 6mm Washer
** 6mm Button Head Bolt
** RS5 Muffler Clamp Heat Insulator
** Scotch Brite (Titanium Sleeve Only)
** Adhesive Foil Heat Shield (8" x 16")
** Aluminum Rear Fender Bracket
** Low Volume Insert Kit
** Yoshimura Vinyl Sticker
Nuts and Bolts Guide (Actual Size):
8mm Flange Nut
6mm Button Head Bolt
Yoshimura EVA Stopper
1 EVA Stopper Plate
2 EVA Stopper Bracket
3 Large 6mm Washer
THIS SIDE UP
2005-2006 Kawasaki ZX6R(R)
Heat Shield Template
All 1462 Systems